M-MANUALS DUMPwiring Red IO en PDF

Application for Process Automation
Configuration of Redundant I/O Modules

Concise Overview with Step-by-Step Instructions

Warranty, Liability and Support
Configuration of Redundant I/O Modules 28430682

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Note The Application Examples are not binding and do not claim to be
complete regarding the circuits shown, equipping and any eventuality.
The Application Examples do not represent customer-specific solutions.
They are only intended to provide support for typical applications. You
are responsible for ensuring that the described products are correctly
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of the other documents have priority.

Warranty, Liability and Support

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Foreword

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Foreword
Purpose of this document
Using PCS 7 applications, this document describes:
Redundant I/O modules especially with channel granular functionality
Setup, wiring and configuration of redundant ET 200M stations
Using Marshalled Termination Assemblies (MTA) as an interface
between the distributed I/O modules and the acutators or sensors
Diagnostics options on a fault-tolerant system with redundant I/Os in
case of an error
Required basic knowledge
This documentation addresses people working in the field of configuration,
commissioning and service with basic knowledge of PCS 7.
Classification within the informational landscape
Further information on the topic of redundancy in PCS 7 and on direct
handling of the individual fault-tolerant components is given in the following
documents. They are part of the software package Process Control System
PCS 7 Toolset V7.0 SP1.
Table 0-1
Document Content
Process Control System PCS 7 V7.0
SP1
Fault-tolerant process control
systems
Solutions for the I/Os
Configuration of fault-tolerant components
Automation system S7-400H
Fault-tolerant sytems
Setup of a CPU 41x-H
Connection of redundant I/O
Distributed I/O ET 200M Setup of ET 200M
Automation system S7-300 module
data
Technical data on signal modules.
Marshalled Termination Assemblies
ET 200M Remote I/O Modules
Commissioning of MTA Boards
Function Manual
PCS 7 Library V70
Description of the PCS 7 channel blocks
Process Control System PCS 7 V7.0
SP1
Released Modules
List of the system-tested SIMATIC modules
released in the PCS 7 environment
Process control system PCS 7 V7.0
Asset Management
Passivation/depassivation of redundant
modules
Distributed I/O ET 200M
HART analog modules
Connecting of actuators / sensors in
redundant operation

Table of Contents

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Table of Contents
Table of Contents ......................................................................................................... 4
1 Introduction..................................................................................................... 5
1.1 Redundant I/O .................................................................................................. 5
1.2 Channel granularity........................................................................................... 5
1.3 Hardware components...................................................................................... 7
1.3.1 Fault-tolerant automation system (AS) ............................................................. 8
1.3.2 Interface modules (IM)...................................................................................... 8
1.3.3 Bus modules..................................................................................................... 9
1.3.4 I/O modules .................................................................................................... 10
1.3.5 Marshalled Termination Assemblies (MTA) .................................................... 11
2 Setup and Wiring .......................................................................................... 14
2.1 Redundant PROFIBUS-DP connection .......................................................... 14
2.2 Redundant connections of the distributed I/O................................................. 14
2.2.1 Digital input: .................................................................................................... 15
2.2.2 Digital output ................................................................................................... 18
2.2.3 Analog input .................................................................................................... 21
2.2.4 Analog output.................................................................................................. 28
2.3 Connection of Marshalled Termination Assemblies........................................ 34
3 Configuring the Redundant I/O ................................................................... 37
3.1 Settings at the CPU........................................................................................ 37
3.2 Configuring the first ET 200M (Interface Module IM 153-2)............................ 41
3.3 Configuring the signal modules ...................................................................... 42
3.4 Configuring the second ET 200M................................................................... 45
3.5 Settings at the signal modules........................................................................ 47
3.6 Configuring the HART field devices................................................................ 51
3.7 Symbolic name assignment ............................................................................ 52
3.8 CFC configuration........................................................................................... 55
4 Function Mechanisms.................................................................................. 57
4.1 Example of a process sequence..................................................................... 57
4.2 Library functions ............................................................................................. 59
4.2.1 PCS 7 Library ................................................................................................. 59
4.2.2 Redundant IO CGP......................................................................................... 59
4.3 OS messages of the modules......................................................................... 60
5 Diagnosis....................................................................................................... 62
5.1 Error scenario ................................................................................................. 62
5.2 OS messages ................................................................................................. 63
5.3 Asset Management ......................................................................................... 64
5.4 HW Config online............................................................................................ 65
5.5 CFC test mode................................................................................................ 67

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1 Introduction
1.1 Redundant I/O
The high-availability in PCS 7 can be principally applied on all levels. In this
documentation the emphasis is placed on the application of redundant
distributed I/O using ET 200M modules. Thereby, particularly the wiring
options of the input/output modules as well as the individual configuration
steps are explained.
The term redundant I/O refers to input/output modules (I/O) which exist
twice with redundant configuration and operation in pairs. The application of
redundant I/Os offers the highest availability as it enables buffering the
failure of a CPU as well as of a signal module.
Marshalled Termination Assemblies (MTA) as interface modules offer the
possibility of connecting field devices, sensors and actuators in a simple,
quick and secure manner to an I/O module of the ET 200M. This document
displays how such MTA are structured, which important features and
advantages they have, and that they can be implemented without extensive
wiring and configuration works.

Note The Automation System S7-400H, fault-tolerant systems manual
contains extensive information on the redundancy mechanisms in the AS
level.

1.2 Channel granularity
Since PCS 7 V7.0 the channel granular redundancy using the Redundant
I/O CGP has been added to the function type module granular
redundancy with library RED_LIB V1.
If for module granular redundancy an error occurs on one of the channels
of the first redundant module, for example, the entire module is passivated
including all channels. If an error then occurs on a different channel of the
second module, then this second error cannot be controlled unless the first
error is repaired and the first module has been depassivated.
The advantage of the channel granular redundancy is the higher availability
at equal hardware setup, and a more precise error search for several
channel errors on a module. Therefore the channel granular redundancy is
stressed in this documentation.
Channel errors either due to discrepancy or due to diagnostic alarm
(OB82), do not lead to passivation of the entire module. Instead, only the
affected channel is passivated. A depassivation activates the affected
channel as well as the module passivated due to module failure. Due to

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channel granular passivation, the availability is clearly increased in the
following cases:
Relatively frequent encoder failures
Long repair duration
Several channel errors on one module

When changing from module granular redundancy to channel granular
redundany you must notice the following points:
For activating the channel granular passivation you must stop the
automation system (general reset and reload of user program in STOP
mode).
Expand the existing projects either with blocks of the RED_LIB (V1)
library or switch entirely to Redundant IO CGP. The FB452
RED_DIAG now calls the SFB 54. For this reason error information is
supplemented for this FB. Therefore you check the calling blocks.
Ensure during conversion of a project that all blocks named FB450-453
and FC450-451 have been deleted from the block folder. Perform this
step in each relevant program. Compile and load your project.

Note Mixing of blocks from libraries RED_LIB (V1) and Redundant IO CGP
in one CPU is not permitted and may cause unpredictable behavior.

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1.3 Hardware components
Principally, the availability can be increased in two ways. On the one hand
via an I/O interconnected as single-channel as illustrated in the example in
Figure 1-1. The discussions in this documentation are mainly restricted to
the usage of redundant I/O with two ET 200M stations.
Figure 1-1
Sensor
Sensor
S7-400H
ET 200M, consists of
2 x IM 153-2 und SMs
Sensor
Sensor
S7-400H
2 x IM 153-2 und SMs

A redundant I/O is exists if the input/output modules for a process signal
are available twice and can be addressed by the AS (S7-400H).
In PCS 7 a redundant I/O can be established with selected S7-300 I/O
modules of the ET 200M series.
The distributed I/O device ET 200M is connected to a fault-tolerant
automation system (DP master) as a DP slave via PROFIBUS DP. A
redundant setup is reached by an additional ET 200M and an additional
PROFIBUS DP connection.
The individual hardware components for setting up a fault-tolerant system
with redundant distributed I/O are further described in the following
sections.

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1.3.1 Fault-tolerant automation system (AS)
The aim for using fault-tolerant automation systems is reducing the risk of
production outage.
For the S7-400H to remain available in any case, it has a redundant
structure. This means that all main components exist twice: the central
processing unit CPU, the power supply and the hardware for coupling both
central processing units.
Table 1-1 shows the CPU types which can be used with PCS 7.
Table 1-1
Designation MLFB FW Version
CPU 414-4H 6ES7 414-4HJ00-0AB0 V3.1
CPU 414-4H 6ES7 414-4HJ04-0AB0 V4.0
CPU 417-4H 6ES7 417-4HL01-0AB0 V3.1
CPU 417-4H 6ES7 417-4HL04-0AB0 V4.0
CPU from PCS 7 V7.0 SP1
CPU 412-3H 6ES7 412-3HJ14-0AB0 V4.5
CPU 414-4H 6ES7 414-4HM14-0AB0 V4.5
CPU 417-4H 6ES7 417-4HT14-0AB0 V4.5

1.3.2 Interface modules (IM)
Interface modules, also referred to as interface module (IM), serve as a
PROFIBUS DP interface in the distributed I/O ET200M. For redundant I/O it
must be ensured, that per ET 200M station two interface modules (IMs) are
used and the same bus address (via DIP switch) has been set for both.
If the active interface module fails during runtime, there will be a bumpless
take-over of the function by the passive interface module. The active
interface is displayed by the LED ACT light on the respective interface
module.
Table 1-2 shows IM modules for redundant applications.
Table 1-2
Designation MLFB FW Version
ET200M-IM153-2 6ES7 153-2BA00-0XB0 V3.x
ET200M-IM153-2 6ES7 153-2BA01-0XB0 V4.x
ET200M-IM153-2 6ES7 153-2BA81-0XB0 V4.x
ET200M-IM153-2 6ES7 153-2BA02-0XB0 V5.x
ET200M-IM153-2 6ES7 153-2BA82-0XB0 V5.x
ET200M-IM 153-2 FO 6ES7 153-2BB00-0XB0 V3.x

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1.3.3 Bus modules
As already mentioned above, for PCS 7 only active bus modules are used
for redundant applications with ET 200M. This enables plugging and pulling
the modules during runtime. For redundant operation two IM 153-2 High
Feature are mounted to the active bus module for an ET 200M.
Further modules are used for the ET 200M standard modules (e.g. DI, DO,
AI, AO).
Figure 1-2 shows a possible setup of an ET 200M station. It must be noted,
that using the redundant power supply module (PS) is optional here.
Figure 1-2
PS PS

PS
Note Permitted combinations between connections and bus modules, as well
as available functionalities are available in the manual SIMATIC
distributed I/O device ET 200M.

For the setup of a redundant ET 200M station an IM 153 redundancy
bundle is often ordered in practice. It consists of two IM 153-2 High Feature
and an active bu8s module IM 153/IM 153.

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1.3.4 I/O modules
I/O modules with channel granular functionality
From PCS 7 V7.0 on you can define how redundant input/output modules
behave during a channel failure (e.g. wire-break, short-circuit on the signal
line). During a channel failure, the following reactions must be expected
depending on the used module and the configuration:
When an error occurs only the faulty channel is passivated
(recommended channel granular passivation method)
The entire module is passivated when an error occurs (module granular
passivation behavior)
The following Table 1-3 shows input and output modules suitable for the
redundant setup with ET200M and equipped with channel granular
functionality. It must be noted here, that modules with channel granular
properties can always also be used for module granular applications,
however, not vice versa.
Table 1-3
Designation MLFB
Digital input module
SM321 DI 16xDC24V, Alarm 6ES7 321-7BH01-0AB0
Digital output module
SM322 DO 16xDC24V/0,5A 6ES7 322-8BH01-0AB0
Analog input module
SM331 AI 8x16Bit 6ES7 331-7NF00-0AB0
SM331 AI 8x0/420mA HART 6ES7 331-7TF01-0AB0
Analog output module
SM332 AO 8x12Bit 6ES7 332-5HF00-0AB0
SM332 AO 8x0/420mA HART 6ES7 332-8TF01-0AB0

Note The application of HART modules requires PCS 7 V7.0 SP1.
Furthermore, certain interface modules (6ES7 153-2BA02-0XB0 or 6ES7
153-2BA82-0XB0) must be used.

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Particularities for HART modules

Note When using redundant HART analog modules, only one measuring
transmitter (encoder) can be connected.

Redundant HART signal modules work as "Primary Master" and
"Secondary Master", in order to enable simultaneous HART communication
via both modules with one field device.
The module with the lowest address is declared by the system as the
"Primary Master". If it fails, the communication occurs via the "Secondary
Master".

Note In order to not affect this system behavior, no further HART masters,
such as handheld, must be connected.

1.3.5 Marshalled Termination Assemblies (MTA)
SIMATIC PCS 7 MTA offers the possibility of connecting field devices,
sensors and actuators in a simple and quick manner to an I/O module of
the distributed I/O ET 200M.
The MTA are tailored to specific I/O modules from the ET 200M range.
MTA versions for standard I/O modules are equally available as for
redundant and safety-directed I/O modules.
Using them expenses and costs for cabling and commissioning can be
reduced significantly and wiring errors can be avoided.
The following figure shows an option for implementing an MTA to two ET
200M stations (with one encoder).

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Figure 1-3
2 x IM 153-2 and SMs
Sensor
MTA
Sensor
MTA

The SIMATIC PCS 7 MTA are connected via 3m or 8m long, prefabricated
cable assemblies to an I/O module.
Product characteristics
MTA are characterized by the following properties:
Redundant voltage supply DC 24 V with LED display
Screw-type terminals for the direct (1:1) connection of the field devices,
sensors and actuators
Securing with LED display for each I/O channel
Preconfigured cable for connecting the MTA with the I/O module
with SUB D connector, 50/25 pole, socket version, for MTA
with Siemens front connector 40/20 pole, socket version, for ET
200M module
Simulation options on board for IBS purposes (wire-break,
connect/disconnect channel)
Tested as SIMATIC PCS 7 system component and approved with
respective certification (FM, UL, CE, ATEX, TV)
Advantages
MTA enables quick and simple cabling with field devices
Direct connection of the field devices
SUB D connector for connecting preassembled cables
One fuse for each channel with LED display

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Redundant voltage supply DC 24 V
Simulation options on board, e.g. for IBS purposes
Support for redundant ET 200M modules
Channel granular protection
Accessibility
Internal potential distribution
Simple maintenance due to plug-type connectors
Faster IBS
Connection options for HART modem at MTA

Note Further detailed information is available in the manual Marshalled
Termination Assemblies ET 200M Remote I/O Modules.

For the MTA it must be noted that an MTA module can only be switched
with certain input/output modules. Table 1-4 shows possible connection
options.
Table 1-4
Product imprint MLFB
MTA 16 channels DI standard 6ES7650-1AC10-3XX0
MTA 8 channels AI standard 6ES7650-1AA50-2XX0
MTA 8 channels AO standard 6ES7650-1AB50-2XX0
MTA 8 channels TC standard 6ES7650-1AF50-2XX0
MTA 8 channels RTD standard 6ES7650-1AG50-2XX0
MTA 24 channels F-DI (failsafe) 6ES7650-1AK10-7XX0
MTA 10 channels F-DI (failsafe) 6ES7650-1AL10-6XX0
MTA 8 channels F-AI (failsafe) 6ES7650-1AH50-5XX0
MTA 10 channels Relais DO 6ES7650-1AM30-6XX0

Note
Detailed information on the individual MTA types is available in the
delivery approval:
http://support.automation.siemens.com/DE/view/en/22538324

Setup and Wiring

2 Setup and Wiring
2.1 Redundant PROFIBUS-DP connection
The transition from automation system to PROFIBUS DP occurs via a CP
443-5 Extended or via one of both internal PROFIBUS DP interfaces of the
CPU.
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2.2 Redundant connections of the distributed I/O
Figure 2-1 gives an example of the connection of the redundant I/O in the
connected DP slave mode. As opposed to the redundant I/O in one-sided
DP slave mode, the signal modules are employed here in the distributed
I/O devices ET 200M.
Figure 2-1

The following chapter describes the connection of the encoders to the
signal modules.

Redundantes Baugruppenpaar
Note Detailed circuit diagrams and module details are available in the manuals
Automation System S7-300 Module Data and Automation System
S7-400H fault-tolerant systems.

Setup and Wiring

2.2.1 Digital input:
Encoder connection
One or two encoders are connected to two redundant SM 321; DI 16 x DC
24 V (2oo2 structure).
Figure 2-2

With one sensor With two sensors
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In order to reach a maximum availability it is recommended to use two
encoders.

Note When connecting an encoder to several digital input modules, the
redundant modules must have the same reference potential.

Setup and Wiring

Connection and principle circuit diagram of SM 321; DI 16 x DC 24 V
The following figure shows the principle circuit diagram of the digital input
module with channel granular functionality (6ES7 321-7BH01-0AB0).
Figure 2-3
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Table 2-1
Number Description
1 Channel number
2 Status display green
Error display red
Encoder supply VS - green
3 Backplane bus connection
4 Wire-break detection

Setup and Wiring

Example
One encoder is connected to two SM 321; DI 16 x DC 24 V at channel 0
respectively.
Figure 2-4
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Setup and Wiring

2.2.2 Digital output
Controlling the final control element
The actuator is connected to two redundant SM 322; DO 16 x DC 24 V /
0.5 A (2oo2 structure). Depending on the type of digital output modules,
additional diodes must be used in redundant operation.

Note The overview of which digital output modules can be wired via external
diodes, are available in the manual Automation systems S7-400H fault-
tolerant systems in table 8-4.

Figure 2-4
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With external diodes Modules with integrated diodes
Aktor

The digital output module with channel granular functionality (6ES7 322-
8BH01-0AB0) is switched without external diodes.

Note The digital output modules must have a joint load voltage supply.

Setup and Wiring

Connection and principle circuit diagram of SM 322; DO 16 x DC 24 V / 0.5 A
The following figure shows the principle circuit diagram of the digital output
module with channel granular functionality (6ES7 322-8BH01-0AB0).
Figure 2-4
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Table 2-2
Number Description
1 Status display green
Error display red
2 Channel number
Numbers 0 to 7 on the right side correspond to
channel numbers 8 to 15
3 Channel status (green)
4 Channel error (red)

Setup and Wiring

Example
An actuator is connected to two SM 322; DO 16xDC 24V/0.5A at channel 8
respectively:
Figure 2-5
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Setup and Wiring

2.2.3 Analog input
Encoder connection
The analog input module SM331; AI 8x16 bit can be used in redundant
operation with one or two encoders (2oo2 structure).
Figure 2-6
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Voltage measurement Direct current measurement
Indirect current measurement
With two sensors

In order to reach a maximum availability it is recommended to use
redundant encoders.

Note When using redundant HART analog modules, only one measuring
transmitter (encoder) can be connected.

Setup and Wiring

Connection and principle circuit diagram of SM 331; AI 8 x 16 bit (voltage
measurement)
The following two figures respectively show the principle circuit diagram of
the analog input module SM331 AI 8x16Bit (6ES7 331-7NF00-0AB0) with
channel granular functionality for voltage and current measurement.

Figure 2-7
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Table 2-3
Number Description
1 Voltage measurement
3 Electrical isolation
4 Analog-digital converter (ADU)
5 Equipotential bonding

Setup and Wiring

Connection and principle circuit diagram SM 331; AI 8 x 16 bit (current
measurement)
For measuring currents the DC terminals of a channel are switched parallel
with the respective current resistor. This occurs by bridging the channel
input terminals with the neighboring terminals of the connection socket.
For example, to configure channel 0 for the current measurement, you
bridge terminals 22 and 2 and terminals 23 and 3 respectively.
In the channel configured for current measurement the current resistance
must be connected to the neighboring channel terminals in order to reach
the specified precision.
4-wire measuring transformer (channel 0) or
2-wire measuring transformer with external supply ( channel 7)
Figure 2-8
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Setup and Wiring

Table 2-4
Number Description
3 Analog-digital converter (ADU)
4 CH 0 for 4-wire measuring transformer
5 CH 7 for 2-wire measuring transformer (with external supply)

Connection and principle circuit diagram SM 331; AI 8 x 0/420 mA HART
The following figure shows the principle circuit diagram of the analog HART
input module SM331 AI 8x0/420 mA (6ES7 331-7TF01-0AB0) with
channel granular functionality .
Figure 2-9
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Setup and Wiring

Example of an SM 331; AI 8 x 16 Bit
For voltage supply the following figure shows the connection of a
transmitter to two AI 8 x 16 bit modules.
Figure 2-10
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Setup and Wiring

Example of an SM 331; AI 8x0/420 mA HART (2-wire measuring transformer)

Note A 2-wire measuring transformer must be connected to two redundant
HART analog modules as 4-wire measuring transducer and be
configured.
Further detailed information is available in the manual Distributed I/O
device ET 200M HART analog modules.

At the front connecter the connections 10 and 11 must not be connected
(see Figure 2-9).
Figure 2-11
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Module 1
Module 2

The wired Z-diodes are necessary if after pulling a module the system shall
continue to run.

Setup and Wiring

Example of an SM 331; AI 8x0/420 mA HART (4-wire measuring transformer)
A 4-wire measuring transducer is connected to two redundant HART
analog input modules:
Figure 2-12
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Module 1
Module 2

The wired Z-diodes are necessary if after pulling a module the system shall
continue to run.

Setup and Wiring

2.2.4 Analog output
Controlling the final control element
For the fault-tolerant controls of a final control element two outputs are
switched parallel (2oo2 structure) by two SM 332; AO 8x12 bit via diodes.
Only analog output modules with current outputs can be operated
redundantly (0 to 20 mA or 4 to 20 mA).
Figure 2-13
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Actuator

Both outputs output half of the value. If one of the modules fails, the still
inactive outputs delivers the complete value.

Setup and Wiring

Connection and principle circuit diagram of SM 332; AO 8 x 12 bit (voltage
output)
The following image shows the principle circuit diagram of the analog
output module SM331 AO 8x16Bit (6ES7 332-5HF00-0AB0) with channel
granular functionality in 2 and 4 line connection for voltage output.
2 line connection without compensation of line resistors
4 line connection with compensation of line resistors
Figure 2-14
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Table 2-5
Number Description
1 DAU
2 Internal supply
4 Functional earth
5 Backplane connection

Setup and Wiring

Connection and principle circuit diagram of SM 332; AO 8 x 12 bit (current
output)
The following image shows the principle circuit diagram of the analog
output module SM331 AO 8x16Bit (6ES7 332-5HF00-0AB0) with channel
granular functionality as current output.
Figure 2-15
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Table 2-6
Number Description
1 DAU
2 Internal supply
4 Functional earth
5 Backplane connection

Setup and Wiring

Connection and principle circuit diagram SM 332; AO 8 x 16Bit, 0/420mA HART
The following figure shows the principle circuit diagram of the analog HART
output module SM331 AI 8x16 bit, 0/420 mA (6ES7 332-8TF01-0AB0)
with channel granular functionality .
Figure 2-16
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Setup and Wiring

Example of an SM 332; AO 8 x 12 Bit
The actuator is connected to two redundant SM 332; AO 8 x 12 bit at
channel 0 respectively.

Figure 2-17
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24V
24V
Ch 0
Ch 0
R
Aktor
M
M

Note Suitable as diodes are, for example, types from the 1N4003 ... 1N4007
series or any other diode with U_r >=200 V and I_F >= 1 A.
It is sensible to separate module earth and load earth. Equipotential
must exist between both

Setup and Wiring

Example of an SM 332; AO 8 x 16Bit, 0/420mA HART
The actuator is connected to two redundant HART analog output modules.
Figure 2-18
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Actuator
Module 1
Module 2

Setup and Wiring

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2.3 Connection of Marshalled Termination Assemblies
MTA offers the fast and simple connection of the field level to the ET 200M
I/O modules. They reduce wiring expenses and prevent errors.
Figure 2-19

Redundant ET 200M
Preassembled cable
with front connector
Note For a maximum availability with redundant encoders two MTA are
required which are switched between the input modules and the
encoders respectively.

Setup and Wiring

The connection from ET 200M modules to MTA occurs via the connection
cable corresponding to the type, as illustrated in the following figure.
Figure 2-20
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Preassembled cable with SUB-D
connector for connection to SIEMENS
PCS 7 MTA
Screwing terminals
for direct connection
to field devices
2 connections for
redundant construction
Preassembled cable with SUB-D
connector for connection to SIEMENS
PCS 7 MTA
Screwing terminals
for direct connection
to field devices
2 connections for
redundant construction

Setup and Wiring

Connection example of sensors at the screw-type terminals of the MTA
The following figure shows the encoder connection at the example of digital
inputs.
Figure 2-21
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Anschluss Kanal 1
Anschluss Kanal 13
Connection channel 1

Anschluss Kanal 1
Anschluss Kanal 13

Note Further detailed information is available in the manual Marshalled
Termination Assemblies ET 200M Remote I/O Modules.

Configuring the Redundant I/O

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3 Configuring the Redundant I/O
The following sections describe the configuration of individual components
of the distributed I/O with PCS 7. It is assumed, that a PCS 7 project has
been created with an H-station using the project wizard.
The following configuration steps are described:
Setting the CPU (H parameters)
Configuring the first ET 200M (interface module IM 153-2)
Configuration of the individual signal module IOs
Configuring the second ET 200M by copying
Redundancy settings at the signal modules
Symbolic name assignment
CFC configuration

3.1 Settings at the CPU
In order to enable the redundant functioning between the AS and the
distributed I/O, certain settings need to be made at the CPU.
Precondition
The PCS 7 project with a SIMATIC H station is opened in the SIMATIC
Manager.
If the channel granuar passivation behavior is required, respective
signal modules must be used for configuring the ET 200M
(see chapter 1.3).


Procedure
Table 3-1
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Activity Screenshot
1. Open the SIMATIC H Station in
HW Config

2. Select the first used CPU on slot 3 of
the rack (0) and select the menu item
Edit > Object Properties.

3. Switch to the Cyclic Interrupts tab.
Via the drop-down list you select the
desired process image partition for the
respective cyclic interrupt OB into
which the channel blocks are
integrated later on.


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Screenshot
4. Switch to the H Parameters.
Note the used data blocks in the
Data block no. field, which are
given as a standard encoder so they
cannot be used otherwise in your
configuration.
From the Passivation bahavior
drop-down list you select the desired
setting (channel granular or module
granular).
In the field Update the Reserve
you click the Calculate button.
These settings are performed for
calculating the monitoring times.

Note:
Here you set how the redundant
input/output modules behave during
channel errors (see chapter 1.4). This
setting applies to all redundantly
configured signal modules connected
at the CPU.
5. In the dialog field which appears you
make all entries in the User program
information field and then click the
Recalculate button.
Click OK to close the dialog box. In the
properties dialog field of the CPU in the
H Parameters the new calculated
values are now added in Calculated
monitoring times (see step 4).


Activity Screenshot
6. Switch to the Cycle/Clock Memory
tab.
At OB 85 call for I/O error you select
Only for incoming and outgoing errors
from the drop-down list.
Close the Properties dialog with "OK".

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Note Further information on the settings at the CPU is available in the manual
PCS 7 Fault-tolerant Process Control Systems.


3.2 Configuring the first ET 200M (Interface Module IM 153-2)
Precondition
The PCS 7 project with a SIMATIC H station is opened in the SIMATIC
Manager.
In HW Config a redundant PROFIBUS DP master system has been
configured at the SIMATIC H station .
The HW Config of the SIMATIC H Station is opened. If the hardware
catalog does not appear, please select the menu item View > Catalog.
Procedure
Table 3-2
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Activity Screenshot
7. In the drop-down menu of the hardware
catalog you select the current PCS 7
profile in the Profile field.
In the catalog you double-click
PROFIBUS DP. In PROFIBUS-DP >
ET 200M of the catalog you select the
suitable redundancy capable
connection module IM 153-2 and draw
it to one of both PROFIBUS DP
segments via drag & drop.
8. In the Properties PROFIBUS Interface
IM 153-2 you enter the address and
click OK.
The connection with the redundant
PROFIBUS DP segment is generated
automatically.


3.3 Configuring the signal modules
The procedure for configuring the standard and HART signal modules is
explained below.
Note Do not add any HART signal modules to the HART field devices as yet.
This work step follows in chapter 3.6.

Precondition
The PCS 7 project with a H-CPU is created and opened in the SIMATIC
Manager.
configured at the SIMATIC H Station.
In HW Config the interface module IM 153-2 has been configured for
the ET 200M at the redundant PROFIBUS DP.
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Procedure
Table 3-3
Activity Screenshot
9. Select the configured IM 153-2. In the
bottom window the module overview is
displayed.


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10. In the hardware catalog at
PROFIBUS-DP > ET 200M you select
the interface module which you have
already moved to the PROFIBUS DP
master system via drag & drop.

11. In the sub-directories you select a
redundancy capable signal module and
move it to a free slot of the IM 153-2
(module overview) via drag & drop.


12. Repeat steps 1-3 for further signal
modules.

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3.4 Configuring the second ET 200M
After configuring the first ET 200M including all required components
(interface module IM 153-2, signal modules), you must now configure the
second redundant ET 200M. It must be noticed here, that a redundant
operation is only possible with modules of equal MLFB. To avoid
configuration errors, it makes sense to copy the first ET 200M and reinsert
it into the same master system.
Precondition
Manager.
configured at the SIMATIC H Station .
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All required signal modules have been configured.
Procedure
Table 3-4
Activity Screenshot
13. HW Config is opened. Select the
already configured ET 200M and copy
it into the clipboard.


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Screenshot
14. Select on of the PROFIBUS DP
segments and add the copied ET
200M.

15. In the PROFIBUS Interface IM 153-2
Properties dialog you assign the
address of the redundant slave and
click OK. Ensure that this address
differs from the address of the first ET
200M.


3.5 Settings at the signal modules
After both ET 200M stations have been configured, various settings need to
be made at the standard and HART signal modules next.
Redundant modules must lie in the process image of the inputs or the
outputs. Redundant modules must only be accessed via the process
image.
Precondition
Manager.
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The redundant ET 200M was configured.
Procedure
Table 3-5
Activity Screenshot
1. HW Config is opened.
Select the first IM 153-2 again.
Double-click on a signal module in the
module view. The dialog Properties of
this module is opened.


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Screenshot
2. Switch to the Addresses tab.
In the Process image drop-down list
you select the desired process image
partition.
3. Then you select the Redundancy tab.
In the Redundany drop-down list you
select the entry 2 modules.
4. Click the Find... button. The dialog
Find Redundant Module opens.


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Screenshot
5. In the Subsystem box you select the
DP master system in which the
redundant signal module is configured.
In the PROFIBUS address field, all
PROFIBUS addresses available at this
DP master system are displayed.
6. In the PROFIBUS Address box you
select the IM 153-2 in which the
redundant signal module is configured.
In the Redundant module field the
redundancy capable signal modules
available in this IM 153-2 are
displayed, for which no redundancy
has yet been configured.
In the Redundant module field you
select the signal module which is to be
used as redundant signal module and
click the OK button.
7. In the Module Overview box, the
redundant signal modules are now
listed.
You can now set additional parameters
(see Notes on additional parameters
according to the table). These
additional parameters are only set for
the input modules DI and AI. Click the
OK button to accept the settings.
8. For redundant switching of all desired
signal modules repeat steps 1 to 7.


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Note for additional parameters
An error through discrepancy of the input value exists if, after the
configured discrepancy time has elapsed, there is an intolerable difference
between the input values. The following parameters need to be set for
configuring the discrepancy:
For digital input modules
Time discrepancy (maximum permitted time in which the redundant
input signals are allowed to differ)
For analog input modules
Tolerance window (configured in percentage of the final value of the
measuring range). Two analog values are equal if they are within
the tolerance window.
Time discrepancy (maximum permitted time in which the redundant
input signals are allowed to be outside the tolerance window)
Value applied (the value applied is the configured value (larger
value/smaller value) of both analog values which is adopted in the
user program)
For further information regarding the additional parameters you use the
online help.


3.6 Configuring the HART field devices
Precondition
Manager.
Settings at the signal modules have been made
Procedure
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Table 3-6
Activity Screenshot
In the hardware catalog you select the
HART field device and drag it to a free
slot of the HART module in the Module
Overview via drag & drop.
2. Double-click the HART field device. In
the dialog field which appears you
assign a name and click on
Assign.. .


Activity
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Screenshot
3. In the Device Selection dialog which
appears you select the respective
device and click OK.
4. Again you select the HART field device
in the Hardware catalog and drag it to a
free slot of the redundancy partner
(HART module of the second
ET 200M) via drag & drop.
After brief loading, the configured field
device of the first ET 200M is
automatically assigned.

3.7 Symbolic name assignment
Symbolic name assignment requires that the input/output modules in HW
Config have been added. If this has happened, you can assign self-
explanatory symbolic names to the inputs and outputs of these modules.
You use these names for connecting CFC plans with the input and output
modules.
Precondition
Manager.
configured at the SIMATIC H Station.
Settings at the signal modules have been made


Procedure
Table 3-7
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Activity Screenshot
In the work space you select one of
both IM 153-2 interface modules.
In the Module Overview all input/output
modules are displayed which you have
added during the hardware
configuration.

2. In the Module Overview you select the
first signal module e.g. "AI8x16Bit".

3. Select the menu command Edit >
Symbols. The dialog Edit Symbols
opens. All absolute addresses of the
inputs of this module are given to you
in the list.
4. Place the cursor into the Symbol
column next to address "EW 512", for
example.
Enter "Temperatur211", for example,
and press the TAB button. The
entered value will be accepted and the
system automatically enters the data
type "WORD".
5. Change to the Comment column.
Here you can enter a suitable
comment, or position the cursor in the
Symbol column in the next line by
pressing the TAB button again.
6. If necessary you edit further symbols
and save your input by clicking the
OK button.
The Edit Symbols dialog is closed.


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Activity Screenshot
7. In the Module Overview you
successively select the individual sig
modules and as
names. To do this, please follow steps
nal
sign the symbolic
2 to 6.


3.8 CFC configuration
After you performed all necessary configurations, it is now necessary to
create CFC plans. Hereby the input/output modules are interconnected with
the respective channel blocks.
Precondition
All necessary input/output modules were configured in HW Config and
the respective symbols were assigned.
CFC plan was created and is opened.
Procedure
Table 3-8
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Activity Screenshot
8. In the bottom left window pane you
select the Libraries tab. Here you
select the path
PCS 7 Library V70 >
Blocks+Templates\Blocks > Driver.
Depending on input/output module you
now draw the driver block CH_AI,
CH_AO, CH_DI or CH_DO into your
plan via drag & drop.

9.
If necessary you draw further blocks
into your plan to interconnect them. For
temperature measurement, for
example, you can interconnect the
channel block with a MEAS_MON, in
order to have the temperature
displayed during runtime later on.

10. For interconnecting the channel block
with your configured input/output
module you select the block and click
the Value button of the channel
block and open the menu command
Insert > Interconnection to
Address.
A symbol table opens.


Activity Screenshot
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11. Click the respective symbol you wish to
connect the block with.
Here you can select the symbols you
have assigned in HW Config during
symbol assignment (see chapter 3.7).

12. During final compilation the module
drivers for the respective modules are
generated automatically. It must be
ensured that Generate module drivers
is check-marked in the appearing
Compile program dialog window.
13. As a result, the MODE input of the
channel block is interconnected with
the @-plans automatically generated
by the system.

Function Mechanisms

4 Function Mechanisms
4.1 Example of a process sequence
The following figure gives an example of a process sequence for redundant
input/output modules and the signal processing in the AS.

NOTE The example shows the use of two sensors. In the process industry the
wiring of a sensor to a redundant module pair is also typical (see chapter
2.2 "Redundant connections of the distributed I/O").

Figure 4-1
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Teilprozessabbild
Aktualisierung
gnge der Ein
AI : EW512
AI : EW560
AS: Zyklus z.B OB35
CH_AO
AI-B en
.
.
.
.
.
.
.
.
.
Redundante
augrupp
AO : AW512
AO : AW544
CH_AI
100 ms
Zyklus
RED_IN
RED_STATUS
OR_M16_C
RED_OUT
TI111"
QCTRL1"
Teilprozessabbild
ktualisierung
der Ausgnge
EW512
EW560
AW512
AW544
R
AO-Ba n
@-Charts
@-Charts
A
edundante
ugruppe
S
TI111" := EW512
QCTRL := AW512
ymboltabelle
T
T
23,5C
23,4C
23,4C
100%
50%
50%
100%
Redundant AI
module
AS: Cycle e.g. OB35
Process image
partition update of
inputs
Symbol table
100ms
cycle
Redundant AO
module
Process image
tion update o

parti f
outputs

Function Mechanisms

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Description of the upper part of the process sequence
In the upper part, two temperature measuring values are recorded by two
encoders via redundant AI modules and are written into the process image
partition of the inputs via two addresses (EW512, EW560).
Depending on the setting of the accepted value (see additional parameter
Table 3-5 point 7) the smaller or larger value is written to the channel block
CH_AI via the respective symbol TI111 in the user program.
The diagnosis and redundancy evaluation is performed via the @-charts, in
which also the blocks of the redundant IO CGP (RED_IN, RED_STATUS,
etc.) and from the PCS 7 Library (OR_M16_C) are located. The block
OR_M16_C forwards the respective diagnosis or redundancy status to the
channel block CH_AI.
Depending on the status the respective redundancy message
characteristics (OR_M16_C, see below) will result automatically.
Description of the bottom part of the process sequence
In the bottom part of the process sequence a control valve is controlled by
two redundant analog output modules.

Note Redundant operation is only possible for output modules with current
outputs (020mA, 420mA). See chapter 2.2.4 Analog output.

From channel block CH_AO a value is written to the previously configured
symbol QCTRL1 into the process image partition of the outputs.
Information is evaluated and respective values are output by the system via
the @-charts and especially via the RED_OUT. This is handled by the
process image partition of the outputs (addresses AW512 and AW544).
The output value is halved and half of the value each is output by both
channels. If a channel or a module fails, this will be detected and the still
remaining channel or module will output the complete value.
The output value will for a short time drop down to half, however, after the
reaction in the program (milliseconds) it will be raised to the proper value.
Due to the inertia of the final control element this has no effect on the
process.

This process sequence is repeated cyclically depending on the call and the
cycle time of the managed OB (in this case OB35every 100 ms).

Function Mechanisms

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4.2 Library functions
The bocks/functions used from PCS 7 Library and Redundant IO CGP are
described below.
4.2.1 PCS 7 Library
OR_M_16C
Block OR_M_16C is used to form a value status, channel granular, of two
redundant signal modules.
MOD-D1
Block MOD_1 monitors the non-diagnosis capable, maximal 16-channel
S7-300/400 SM module (no mixed groups).
For H systems, only modules in switched module racks are supported.
4.2.2 Redundant IO CGP
RED_IN
The FB 450 handles the reading of signals of the redundant input I/O (DI,
AI), which is assigned to the process image partition of the priority class of
the calling OB.
The FB 450 performs a discrepancy analysis of the redundant input I/O and
saves the valid value to the lower address in the process image of the
inputs (PAE). The user must only access this one in his application. The
PAE of the high module is irrelevant.
RED_STATUS
The FB 453 RED_STATUS provides an interface block and contains
information regarding the passivation of blocks.
RED_OUT
The FB 451 outputs those redundant I/O signals which are assigned to the
process image partition of the priority class of the calling OB.
RED_DIAG
The FB 452 RED_DIAG evaluates the start information of individual error
and diagnosis OBs to point to a respective processing sequence.
It is called in acyclic OBs (e.g. OB 82, OB 85).
RED_DEPA
With this function a depassivation is triggered by the user program.
The FC checks whether a redundant module or a channel is passivated. If
a module or a channel is passivated, an overall depassivation is triggered

Function Mechanisms

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in FB 450 RED_IN. In a different case (there is no passivation of a module
or a channel) processing of FC 451 is terminated immediately.
The function is called in acyclic OBs (e.g. OB 82, OB 85).
RED_INIT
The I/O redundancy is initialized during the startup of an H system using
the FC 450 RED_INIT.
When called up, the FC 450 creates administration data blocks for the
functional I/O redundancy and assigns them with default values or it
updates already existing administration DBs. The function triggers an
overall depassivation which is then executed in FB 450 RED_IN.
The function is called in acyclic OBs (e.g. OB 82, OB 85).
4.3 OS messages of the modules
The following module elements are created in the OS by means of OS
compilation.
Redundancy message characteristics (OR_M_16C)
BG x/y/z: failure of module redundancy pair
BG x/y/z: modules redundancy loss
BG x/y/z: module status cannot be determined
BG x/y/z: discrepancy time has elapsed
BG x/y/z: failure of redundancy pair channel xx

Table 4-1
Letter Description
X DP master system no.
Y Y - DP slave address
Z Z slot no
XX Channel no

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Message characteristics of a diagnosis capable module (MOD_D1)
Possible module errors (output parameter QMODF = TRUE):
External auxiliary voltage missing
Front connector missing
Module not configured
wrong parameters in module
Module missing/wrong
Communication failure CPU module
Time monitoring responded (watch-dog)
BG internal supply voltage failed
Module rack failure
Processor failure
EPROM error
RAM error
ADU/DAU error
Fuse tripped
Power supply 1: error
Power supply 2: error
Possible channel failure (value status "invalid value", OMODE_xx =
16#00xxxx):
Configuration/parameterization error
Common mode error, only analog input/output
P short-circuit
M short-circuit
Output transistor interrupted
Wire break
Reference channel error (only analog input)
Below measuring range (only analog input)
Above measuring range (only analog input)
Load voltage missing (only analog and digital output)
Encoder voltage missing (only digital output)
Fuse tripped (only digital output)
Mass error (only digital input/output)
Overtemperature (only digital output)

Diagnosis

5 Diagnosis
In this chapter an example for the diagnostic possibilities with PCS 7 is
illustrated with regards to redundant I/O.
5.1 Error scenario
Within the running system a channel error due to wire break at a digital
input module is simulated.
Figure 5-1
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S7-400H
ET 200M, bestehend aus 2 x
IM 153-2 und SMs

It must be noted, that in this example channel granular components are
used. The wire-break at a connection of the digital input module does
therefore not passivate the entire module, but only the faulty channel (or
channel group). The following diagnosis options exist for the error:
OS messages
Asset management
HW Config
CFC test mode
In the practical environment the error first becomes visible for the operator
in the control center on the OS. There, the maintenance engineer will first
have the respective message list displayed to him.
Parallel he receives further information on the status of the signal module
via the asset management. From the asset management there is the option
to switch to HW Config via a button in order to receive further diagnostic
entries in the module status of H-CPU and signal module.
Encoder
MTA
Wire-break for digital input module
ET 200M consisting of 2 x IM
153-2 and SMs

Diagnosis

Parallel, further status values of the signal module are available in the CFC
test mode.

5.2 OS messages
In the OS you will receive respective error messages via the Incoming
alarm list button.
Figure 5-2
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Diagnosis

5.3 Asset Management
If Asset Management has been implemented in your PCS 7 project, then
you also receive information on errors of the redundant I/O.
Figure 5-3
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Note Further information is available in the manual Process Control System
PCS 7 V7.0 Asset Management in the chapter
Passivation/depassivation of redundant modules.

Diagnosis

5.4 HW Config online
Diagnostic buffer
In the online mode in HW Config you can see the displayed events
messages, which are displayed in Figure 5-4, in the Module Information of
the H-CPU in the Diagnostic Buffer tab. Apart from the error messages
information on the behavior of the modules are also listed here.
The wire break is listed here in the Events field by no. 20 to no. 23. By
marking the respective message further information is displayed in the
Details on Event field.
Figure 5-4
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Diagnosis

Diagnostic alarm
A further diagnostic option in HW Config is the Module status of the signal
module (Figure 5-5). Here you find a Standard Diagnosis of the Module
and the Channel-Specific Diagnosis in the Diagnostic Interrupt tab.
Figure 5-5
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A mouse-click on the Display button yields further information on the
selected diagnostic line.

Diagnosis

5.5 CFC test mode
The value status of the redundant signal modules is diagnosed in the CFC
plan using OR_M_16C (Figure 5-6).
The various connections of the block can be logged on here.
Figure 5-6
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Due to the wire-break status, 16#FFFF is an invalid value at connection
MODE1_00.
Connection MODE1_00 displays the status for channel 0 of the primary
digital input module.
The connection MODE2_00 displays the status for channel 0 of the second
redundant digital input module. With 16#8000FFFF there is a valid value at
connection MODE2_00.

Diagnosis

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The following table shows further connection properties of OR_M_16C:
Table 5-1
Connection Meaning Data
Type
Default
setting
Type
MODE1_xx Operating mode channel (xx = 00 07 / 00
15)
of the primary module
DWORD 0 I
MODE2_xx Operating mode channel (xx = 00 07 / 00
15)
of the redundant module
DWORD 0 I
OMODE_xx Operating mode channel (xx = 00 07 / 00
15)
DWORD 0 O
QDISCREP 1 = discrepancy time elapsed BOOL 0 O
QMODF1 1 = error module 1 BOOL 0 O
QMODF2 1 = error module 2 BOOL 0 O

Note Further information regarding the connections of OR_M_16 as well as its
error messages are available in the manual PCS 7 Library V70.

Examples for the value status
Byte 3:
16#80: value status "valid value"
16#00: value status "invalid value" (channel error)
16#40: value status "invalid value" (higher-level error)
Byte 2:
16#01: OB 100 restarted
16#02: measuring range exceeded (diagnostic channel error)
16#04: measuring range fallen short of (diagnostic channel error)

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Application for Process Automation

Configuration of Redundant I/O Modules

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